Engagement features and methods for attaching a drive rod to a knife blade in an articulating surgical instrument

ABSTRACT

A knife assembly for use with a surgical instrument includes a knife having proximal and distal ends, the proximal end including an aperture defined therein having a series of spaced apart fins extending thereacross. A knife drive rod is included and is configured to operably engage the fins to secure the knife drive rod to the knife. A retention mechanism is operably disposed at a distal end of the knife drive rod and is configured to secure the knife drive rod in engagement between the fins.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/832,782, filed on Mar. 27, 2020, which claims the benefit of andpriority to U.S. Provisional Patent Application No. 62/825,882, filed onMar. 29, 2019, the entire contents of each of which is incorporated byreference herein.

BACKGROUND Technical Field

The present disclosure relates surgical instruments, and moreparticularly, to various engagement features and methods for attaching adrive rod to a knife blade to facilitate actuation thereof.

Background of Related Art

A surgical forceps is a pliers-like instrument that relies on mechanicalaction between its jaw members to grasp, clamp, and constrict tissue.Electrosurgical forceps utilize both mechanical clamping action andenergy to heat tissue to treat, e.g., coagulate, cauterize, or seal,tissue. Typically, once tissue is treated, the surgeon has to accuratelysever the treated tissue. Accordingly, many electrosurgical forceps aredesigned to incorporate a knife or cutting member utilized toeffectively sever the treated tissue.

Many electrosurgical forceps include various actuators to orient the jawmembers for tissue treatment. For example, many forceps includerotational wheels (or the like) disposed in proximity to a surgeon'shands to enable the surgeon to selectively rotate the jaw members asneeded during an operation. A trigger (or similar) may be disposed onthe forceps housing to allow a surgeon to selectively deploy a knife orcutting element as needed during surgery. Other actuators includearticulating mechanisms disposed in proximity to the surgeon's hands toallow the surgeon to selectively articulate (e.g., pitch and yaw) thejaw members as needed during surgery.

With particular respect to articulating forceps that include adeployable knife, one important feature of these types of forceps is theknife drive rod which typically needs to be both sufficiently flexibleto allow articulation of the jaw members while also being strong enoughto advance and retract a knife blade through tissue.

SUMMARY

As used herein, the term “distal” refers to the portion that is beingdescribed which is further from a user, while the term “proximal” refersto the portion that is being described which is closer to a user.Further, to the extent consistent, any or all of the aspects detailedherein may be used in conjunction with any or all of the other aspectsdetailed herein.

In accordance with aspects of the present disclosure, a knife assemblyfor use with a surgical instrument is provided and includes a knifehaving proximal and distal ends. The proximal end of the knife includesan aperture defined therein having a series of spaced apart finsextending thereacross. A knife drive rod is configured to operablyengage the fins to secure the knife drive rod to the knife, and aretention mechanism is operably disposed at a distal end of the knifedrive rod and is configured to secure the knife drive rod in engagementbetween the fins.

In aspects according to the present disclosure, the retention mechanismis a cap or any other type of enlarged area at a distal end thereof,e.g., forged head, molten bubble, additional material via welding,crimping, swaging, etc. In other aspects according to the presentdisclosure, the retention mechanism includes the knife having a secondaperture defined therein configured to receive a bent end of the knifedrive rod.

In aspects according to the present disclosure, one or more of the finsincludes a recess defined therein configured to receive at least aportion of an outer periphery of the knife drive rod. In still otheraspects according to the present disclosure, the knife drive rod isconfigured to engage the fins in a weave-like manner from a proximal endof the aperture to a distal end of the aperture.

In accordance with additional aspects of the present disclosure, a knifeassembly for use with a surgical instrument is provided and includes aknife having proximal and distal ends, the proximal end including anaperture defined therein. A knife drive rod includes a tube operablyengaged to a distal end thereof. The tube is configured to operablyengage the aperture to lock the knife drive rod in engagement with theknife. In aspects according to the present disclosure, a weld operablyengages the tube to the knife. In other aspects according to the presentdisclosure, the distal end of the knife drive rod threadably engages thetube. In still other aspects according to the present disclosure, theknife and the tube are made from similar metals to increase the strengthof the weld.

In yet other aspects according to the present disclosure, the tube isdimensioned to seat within the aperture and, once seated, provides afirst mechanical engagement between the tube and the knife, and a weldprovides a second mechanical engagement between the tube and the knife.Other methods of mechanical engagement are contemplated, e.g., crimpingand swaging. In still other aspects according to the present disclosure,the knife includes a second aperture defined therein configured toreceive a bent end of the knife drive rod to provide a second mechanicalengagement between the knife and the knife drive rod. In other aspectsaccording to the present disclosure, the second aperture is a slot andthe bent end of the knife includes a locking feature to secure thedistal end of the knife drive rod within the slot once engaged therein.In yet other aspects according to the present disclosure, the lockingfeature is a twist lock, a tab lock, a button snap, a crimp, or a rivet.

In accordance with additional aspects of the present disclosure, a knifeassembly for use with a surgical instrument includes a knife havingproximal and distal ends. The proximal end includes an aperture definedtherein including a pair of tubes operably engaged thereto. A knifedrive rod is configured to operably engage the pair of tubes disposedwithin the aperture. A knife tube is operably engaged to the knife driverod between the pair of tubes. The knife tube is dimensioned larger thanthe pair of tubes to lock the knife drive rod within the pair of tubesand in operable engagement with the knife.

In aspects according to the present disclosure, a weld secures each tubeof the pair of tubes to the knife, and a knife weld secures the knifetube to the knife drive rod. In yet other aspects according to thepresent disclosure, the pair of tubes and the knife are made fromsimilar metals, and the knife tube and the knife drive rod are made fromsimilar materials to increase the strength of the welds.

In accordance with additional aspects of the present disclosure, a knifeassembly for use with a surgical instrument includes a knife havingproximal and distal ends. The proximal end includes an aperture definedtherein having one or more capture tabs disposed therein. A tube isconfigured to operably engage the one or more capture tabs disposedwithin the aperture. A knife drive rod is configured to operably engagethe tube disposed within the aperture.

In aspects according to the present disclosure, the knife drive rodthreadably engages the tube. In other aspects according to the presentdisclosure, the tube is dimensioned to seat within the aperture and,once seated, provides a first mechanical engagement between the tube andthe knife, and a weld provides a second mechanical engagement betweenthe tube and the knife. In aspects according to the present disclosure,the aperture includes a pair of opposing capture tabs each configured toengage an end of the tube.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects and features of the present disclosure willbecome more apparent in view of the following detailed description whentaken in conjunction with the accompanying drawings wherein likereference numerals identify similar or identical elements and:

FIG. 1A is a perspective view of endoscopic surgical forcepsexemplifying the aspects and features of the present disclosure, whereinthe shaft of the endoscopic surgical forceps is disposed in anon-articulated position and wherein the jaw members of the endoscopicsurgical forceps are disposed in a spaced-apart position;

FIG. 1B is a perspective view of the endoscopic surgical forceps of FIG.1A, wherein the shaft of the endoscopic surgical forceps is disposed inan articulated position and wherein the jaw members of the endoscopicsurgical forceps are disposed in an approximated position;

FIGS. 2A and 2B are enlarged schematic views of one embodiment of anengagement feature for coupling a knife blade to a knife drive rodexemplifying the aspects and features of the present disclosure;

FIGS. 3A, 3B and 3C are enlarged schematic views of another embodimentof an engagement feature for coupling a knife blade to a knife drive rodexemplifying the aspects and features of the present disclosure;

FIGS. 4A and 4B are enlarged schematic views of another embodiment of anengagement feature for coupling a knife blade to a knife drive rodexemplifying the aspects and features of the present disclosure;

FIGS. 5A, 5B and 5C are enlarged schematic views of another embodimentof an engagement feature for coupling a knife blade to a knife drive rodexemplifying the aspects and features of the present disclosure;

FIGS. 6A, 6B and 6C are enlarged schematic views of another embodimentof an engagement feature for coupling a knife blade to a knife drive rodexemplifying the aspects and features of the present disclosure;

FIGS. 7A, 7B and 7C are enlarged schematic views of another embodimentof an engagement feature for coupling a knife blade to a knife drive rodexemplifying the aspects and features of the present disclosure;

FIGS. 8A, 8B and 8C are enlarged schematic views of another embodimentof an engagement feature for coupling a knife blade to a knife drive rodexemplifying the aspects and features of the present disclosure;

FIGS. 9A, 9B and 9C are enlarged schematic views of another embodimentof an engagement feature for coupling a knife blade to a knife drive rodexemplifying the aspects and features of the present disclosure; and

FIG. 10 is an enlarged schematic view of another embodiment of anengagement feature for coupling a knife blade to a knife drive rodexemplifying the aspects and features of the present disclosure.

DETAILED DESCRIPTION

Referring generally to FIGS. 1A and 1B, an endoscopic surgical forcepsexemplifying the aspects and features of the present disclosure is showngenerally identified by reference numeral 10. For the purposes herein,endoscopic surgical forceps 10 is generally described. Aspects andfeatures of endoscopic surgical forceps 10 not germane to theunderstanding of the present disclosure are omitted to avoid obscuringthe aspects and features of the present disclosure in unnecessarydetail.

Forceps 10 includes a housing 20, a handle assembly 30, a triggerassembly 60, a rotating assembly 70, a plurality of articulationactuators 80, an activation switch 4, and an end effector assembly 100.Forceps 10 further includes a shaft 12 having a distal end 12 aconfigured to mechanically engage end effector assembly 100 and aproximal end 12 b that mechanically engages housing 20. Forceps 10 alsoincludes cable 2 that connects forceps 10 to an energy source (notshown), e.g., a generator or other suitable power source, althoughforceps 10 may alternatively be configured as a battery-powered device.Cable 2 includes a wire (or wires) (not shown) extending therethroughthat has sufficient length to extend through shaft 12 in order toprovide energy to one or both tissue-treating plates 114, 124 of jawmembers 110, 120, respectively, of end effector assembly 100. Activationswitch 4 is coupled to tissue-treating plates 114, 124 and the source ofenergy for selectively activating the supply of energy to jaw members110, 120 for treating, e.g., cauterizing, coagulating/desiccating,and/or sealing, tissue.

Shaft 12 of forceps 10 defines a distal segment 13 positioned towardsdistal end 12 a thereof, a proximal segment 14 positioned towardsproximal end 12 b thereof, and an articulating section 15 disposedbetween the distal and proximal segments 13, 14, respectively.Articulating section 15 includes a plurality of articulating links 16having a plurality of articulation cables 17 extending therethrough.Each cable 17 is operably engaged at a distal end thereof to distalsegment 13 and at a proximal end thereof to one of the articulationactuators 80 to enable articulation of distal segment 13 and, thus, endeffector assembly 100, relative to proximal segment 14 upon actuation ofone or more of articulation actuators 80. Rotating assembly 70 operablycouples shaft 12 to housing 20 to enable selective rotation of shaft 12and, thus, end effector assembly 100, relative to housing 20.

Handle assembly 30 of forceps 10 includes a fixed handle 50 and amovable handle 40. Fixed handle 50 is integrally associated with housing20 and handle 40 is movable relative to fixed handle 50. Movable handle40 of handle assembly 30 is operably coupled to a drive assembly (notshown) that, together, mechanically cooperate to impart movement of oneor both of jaw members 110, 120 of end effector assembly 100 about apivot 103 between a spaced-apart position (FIG. 1A) and an approximatedposition (FIG. 1B) to grasp tissue between jaw members 110, 120. Asshown in FIG. 1A, movable handle 40 is initially spaced-apart from fixedhandle 50 and, correspondingly, jaw members 110, 120 of end effectorassembly 100 are disposed in the spaced-apart position. Movable handle40 is compressible from this initial position to a compressed positioncorresponding to the approximated position of jaw members 110, 120 (FIG.1B).

Trigger assembly 60 includes a trigger 62 coupled to housing 20 andmovable relative thereto between an un-actuated position and an actuatedposition. Trigger 62 is operably coupled to a cutting mechanism 85,various embodiments of which are detailed below, to actuate the cuttingmechanism 85 to cut tissue grasped between jaw members 110, 120 of endeffector assembly 100 upon actuation of trigger 62. As an alternative toa pivoting trigger 62, a slide trigger, push-button, toggle switch, orother suitable actuator may be provided.

End effector assembly 100, as noted above, includes first and second jawmembers 110, 120. Each jaw member 110, 120 includes a proximal flangeportion 111, 121, an outer insulative jaw housing 112, 122 disposedabout the distal portion (not explicitly shown) of each jaw member 110,120, and a tissue-treating plate 114, 124, respectively. Proximal flangeportions 111, 121 are pivotably coupled to one another about pivot 103for moving jaw members 110, 120 between the spaced-apart andapproximated positions, although other suitable mechanisms for pivotingjaw members 110, 120 relative to one another are also contemplated. Thedistal portions (not explicitly shown) of the jaw members 110, 120 areconfigured to support jaw housings 112, 122, and tissue-treating plates114, 124, respectively, thereon.

Outer insulative jaw housings 112, 122 of jaw members 110, 120 supportand retain tissue-treating plates 114, 124 on respective jaw members110, 120 in opposed relation relative to one another. Tissue-treatingplates 114, 124 are formed from an electrically conductive material,e.g., for conducting electrical energy therebetween for treating tissue,although tissue-treating plates 114, 124 may alternatively be configuredto conduct any suitable energy, e.g., thermal, microwave, light,ultrasonic, etc., through tissue grasped therebetween for energy-basedtissue treatment. As mentioned above, tissue-treating plates 114, 124are coupled to activation switch 4 and the source of energy (not shown),e.g., via the wires (not shown) extending from cable 2 through forceps10, such that energy may be selectively supplied to tissue-treatingplate 114 and/or tissue-treating plate 124 and conducted therebetweenand through tissue disposed between jaw members 110, 120 to treattissue.

One or both of jaw members 110, 120 may further define alongitudinally-extending channel 125 (only the channel 125 of jaw member120 is shown) for allowing reciprocation of the cutting mechanism 85upon actuation of trigger 62. Actuation of the trigger 62 reciprocates aknife drive bar, e.g., knife drive rod 280 of FIG. 2B, operably coupledto the cutting mechanism, e.g., knife 285. As explained below, the term“rod” is generally utilized herein but is meant to denote any type ofdrive member or element. Together and as used herein, the knife, e.g.,knife 285 and knife drive bar, e.g., knife drive rod 280, form a knifeassembly 250. Knife drive rod 280 is made from a flexible material ofsufficient strength to allow the knife drive rod 280 to both push andpull the knife 285 through tissue disposed between jaw members 110, 120.Moreover, the flexibility of the knife drive rod 280 allows the knifedrive rod 280 to flex as needed during articulation of the jaw members110, 120. The knife drive rod 280 may be made from a variety of flexiblematerials such as Nitinol that exhibit the necessary strength andflexibility to allow smooth translation of the knife drive rod 280through one or more articulating joints of articulating section 15,e.g., Stainless Steel, High Carbon Steel, Iconel, Monel, Nimonic,Nitronic, Hastelloy (Nickel-based alloys other than Nitonol), Elgiloy(Cobalt-Nickel), Brass, Phosphor Brass, Beryllium Copper,Chrome-Vanadium, Chrome Silicone, Titanium and Braided Cable made ofsteel or Tungsten.

The knife drive rod 280 generally refers to a drive member that may bein the shape of a rod, cable, braided cable, tube, piece of sheet metalor plastic, screw and the like. It is envisioned that the term “rod”covers all of these and other commonly known types of drive members madefrom a variety of different materials so long as it is strong enough,durable enough and/or stiff enough to advance and retract the knife 285.

Knife 285 is typically made from a stronger, harder, stiffer and/or moredurable material, e.g., stainless steel, to allow the knife 285 toeasily translate through tissue on a repeated basis. Other materials arealso contemplated such as Stainless Steel or High Carbon Steel, ToolSteel, High Speed Steel, Chrome Steel, Tungston Carbide, Titanium,Vanadium Alloys, Ceramic or Glass and/or Plastic.

Since it is often difficult to assure a consistent and strong weldbetween two dissimilar metals, i.e., utilizing a flexible firstmaterial, e.g., Nitinol, for the knife drive rod 280 with a secondstronger material for the knife 285, e.g., stainless steel, variouswelding and mechanical capture techniques are described below withrespect to FIGS. 2A-10 .

FIGS. 2A and 2B show one embodiment of a knife 285 for engagement to aknife drive rod 280. More particularly, knife 285 includes a knife body284 having a distal end 286 and a proximal end 282, the distal end 286including a sharpened edge for cutting tissue and the proximal end 282including an aperture 287 defined therein for capturing the knife driverod 280. Together the knife 285 and knife drive rod 280 form a knifeassembly 250. A series of fins 283 are etched from the proximal end 282into the aperture 287 that include one or more recessed portions 283′defined therein configured to partially receive the outer periphery ofthe knife drive rod 280 to mechanically capture the knife drive rod 280on opposing sides along the length thereof. During assembly, the knifedrive rod 280 is weaved through the various fins 283 to engage therecesses 283′ and secure the knife drive rod 280 to the knife 285.Weaving the knife drive rod 280 through the fins 283 provides lateralstability to the knife 285 and knife drive rod 280 during use. Once theknife drive rod 280 is weaved through the fins 283, a retentionmechanism, e.g., a cap 281, is secured (e.g., welded, crimped, etc.) tothe end of the knife drive rod 280 to lock the knife drive rod 280 inplace within aperture 287 of knife 285. Other types of enlarged areasmay be utilized as a retention mechanism, e.g., forged head, moltenbubble, additional material via welding, crimping, swaging, etc. Thedimensions of the cap 281 are sized greater than the dimensions of therecesses 283′ to prevent slippage of the mechanical connection duringuse. The knife 285 may be made from stainless steel, e.g., surgicalstainless steel (316 SS) or other surgical metal, and the knife driverod 280 may be made from Nitinol or other flexible metal or a metalhybrid (Nitinol inner rod and helical hollow strand HHS outer casing).

FIGS. 3A-3C show another embodiment of a knife 385 for engagement to aknife drive rod 380. More particularly, knife 385 includes a knife body384 having a distal end 386 and a proximal end 382, the distal end 386including a sharpened edge for cutting tissue and the proximal end 382including an aperture 387 defined therein for capturing the knife driverod 380. Together the knife 385 and knife drive rod 380 form a knifeassembly 350. A series of fins 383 are etched from the proximal end 382into the aperture 387 that include one or more recessed portions 383′defined therein configured to partially receive the outer periphery ofthe knife drive rod 380 to mechanically capture the knife drive rod 380on opposing sides along the length thereof.

During assembly, the knife drive rod 380 is weaved through the variousfins 383 to engage the recesses 383′ and secure the knife drive rod 380to the knife 385. As mentioned above, weaving the knife drive rod 380through the fins 383 provides lateral stability to the knife 385 andknife drive rod 380 during use. Once the knife drive rod 380 is weavedthrough the fins 383, a retention mechanism, e.g., a bent end 381disposed at the distal end of the knife drive rod 380, is secured withina corresponding aperture 389 defined within the proximal end 382 of theknife body 384 (FIG. 3B) to lock the knife drive rod 380 in place withinaperture 389 of knife body 384 (FIG. 3C).

FIGS. 4A and 4B show another embodiment of a knife 485 for engagement toa knife drive rod 480. More particularly, knife 485 includes a knifebody 484 having a distal end 486 and a proximal end 482, the distal end486 including a sharpened edge for cutting tissue and the proximal end482 including an aperture 487 defined therein for capturing the knifedrive rod 480. Together the knife 485 and knife drive rod 480 form aknife assembly 450. A pair of opposing capture tabs 481 a and 481 b areetched from the proximal end 482 into the aperture 487 and areconfigured to capture and secure a tube 483 therebetween. The innerperiphery of the tube 483 is configured to engage, e.g., threadablyengage, the knife drive rod 480. During assembly, the tube 483 and theknife drive rod 480 may be spot-welded or crimped after engagementwithin the tube 483 to provide additional engagement of the knife driverod 480 therein.

Since the knife drive rod 480 needs to be flexible to accommodatearticulation of the jaw members 110, 120, and the knife body 484 needsto be sufficiently strong to cut through tissue on a repeated basis, theknife drive rod 480 and the knife body 484 are typically made fromdissimilar materials and any such weld or bond may be weaker thandesired. Thus, additional mechanical engagement between the twoelements, e.g., the knife drive rod 480 and knife body 484, is needed toprevent mechanical failure. Tube 483 may be made from any type of metal,e.g., stainless steel, that will provide a secure weld to knife body484. In embodiments, the knife body 484 and the tube 483 are made fromthe same material, e.g., stainless steel, to assure a good weld.

By providing a strong mechanical connection between the knife drive rod480 and the tube 483 and a strong mechanical connection between the tube483 and the knife body 484, the chances of mechanical failure aregreatly reduced.

FIGS. 5A-5C show another embodiment of a knife 585 for engagement to aknife drive rod 580. More particularly, knife 585 includes a knife body584 having a distal end 586 and a proximal end 582, the distal end 586including a sharpened edge for cutting tissue and the proximal end 582including an aperture 587 defined therein for capturing the knife driverod 580. Together the knife 585 and knife drive rod 580 form a knifeassembly 550. A capture tab 581 is etched from the proximal end 582 intothe aperture 587 and is configured to capture and secure a tube 583therein. The inner periphery of the tube 583 is configured to engage,e.g., threadably engage, the knife drive rod 580. During assembly, thetube 583 and the knife drive rod 580 may be spot-welded or crimped afterengagement within the tube 583 to provide additional engagement of theknife drive rod 580 therein.

Since the knife drive rod 580 needs to be flexible to accommodatearticulation of the jaw members 110, 120, and the knife body 584 needsto be sufficiently strong to cut through tissue on a repeated basis, theknife drive rod 580 and the knife body 584 are typically made fromdissimilar materials and any such weld or bond may be weaker thandesired. Thus additional mechanical engagement between the two elements,e.g., the knife drive rod 580 and knife body 584, is needed to preventmechanical failure. Tube 583 may be made from any type of metal, e.g.,stainless steel, that will provide a secure weld to knife body 584.

In embodiments, the knife body 584 and the tube 583 are made from thesame material, e.g., stainless steel, to assure a good weld. The tube583 may be dimensioned to securely seat within aperture 587 afterassembly of the knife drive rod 580 within aperture 587 and aboutcapture tab 586 to provide additional mechanical engagement between theknife body 584 and the knife drive rod 580. By providing a strongmechanical connection between the knife drive rod 580 and the tube 583and a strong mechanical connection between the tube 583 and the knifebody 584, the chances of mechanical failure are greatly reduced.

FIGS. 6A-6C show another embodiment of a knife 685 for engagement to aknife drive rod 680. More particularly, knife 685 includes a knife body684 having a distal end 686 and a proximal end 682, the distal end 686including a sharpened edge for cutting tissue and the proximal end 682including an aperture 687 defined therein for capturing the knife driverod 680. Together the knife 685 and knife drive rod 680 form a knifeassembly 650. A pair of capture tubes 681 a and 681 b is welded (orotherwise formed) into aperture 687 of proximal end 682 and isconfigured to capture and secure a knife drive rod 680 therein. Theinner periphery of the capture tubes 681 a, 681 b are configured toengage, e.g., threadably engage, the knife drive rod 680. Opposingcapture tabs (not shown but see FIG. 4 a —capture tabs 481 a, 481 b) maybe utilized to mechanically capture tubes 681 a, 681 b.

During assembly, the knife drive rod 680 is threaded through the pair ofcapture tubes 681 a, 681 b and a second tube 689 (FIG. 6C) is spotwelded to the exposed portion of the knife drive rod 680 between thepair of capture tubes 681 a, 681 b to secure the knife drive rod 680 inplace between the two capture tubes 681 a, 681 b. The second tube 689 ismade from the same material, e.g., Nitinol, as the knife drive rod 680to assure a strong weld and secure mechanical engagement between theknife drive rod 680 and the capture tubes 681 a, 681 b of the knife body684.

FIGS. 7A-7C show another embodiment of a knife 785 for engagement to aknife drive rod 780. More particularly, knife 785 includes a knife body784 having a distal end 786 and a proximal end 782, the distal end 786including a sharpened edge for cutting tissue and the proximal end 782including a slot 787 defined therein and configured to capture a tube781 crimped, threaded or welded onto a portion of the knife drive rod780. Together the knife 785 and knife drive rod 780 form a knifeassembly 750.

Since the knife drive rod 780 needs to be flexible to accommodatearticulation of the jaw members 110, 120, and the knife body 784 needsto be sufficiently strong to cut through tissue on a repeated basis, theknife drive rod 780 and the knife body 784 are typically made fromdissimilar materials and any such weld or bond may be weaker thandesired. Thus additional mechanical engagement between the two elements,e.g., the knife drive rod 780 and knife body 784, is needed to preventmechanical failure. Tube 781 may be made from any type of metal, e.g.,stainless steel, that will provide a secure weld to knife body 784.

In embodiments, the knife body 784 and the tube 781 are made from thesame material, e.g., stainless steel, to assure a good weld. Theproximal end 782 of the knife body 780 also includes an aperture 789defined therein configured to receive the distal end 783 of the knifedrive rod 780. More particularly, the distal end 783 of the knife rod780 is bent at an angle, e.g., 90°, such that during assembly the distalend 783 may be inserted into aperture 789 to secure the knife drive rod780 to the knife body 784. In addition and during assembly the tube 781is seated within slot 787 to capture the tube 781 therein and provideadditional mechanical engagement between the knife drive rod 780 and theknife body 784 (See FIG. 7C).

FIGS. 8A-8C show another embodiment of a knife 885 for engagement to aknife drive rod 880. More particularly, knife 885 includes a knife body884 having a distal end 886 and a proximal end 882, the distal end 886including a sharpened edge for cutting tissue and the proximal end 882including a slot 887 defined therein and configured to capture a tube881 crimped, threaded or welded onto a portion of the knife drive rod880. Together the knife 885 and knife drive rod 880 form a knifeassembly 850.

Since the knife drive rod 880 needs to be flexible to accommodatearticulation of the jaw members 110, 120, and the knife body 884 needsto be sufficiently strong to cut through tissue on a repeated basis, theknife drive rod 880 and the knife body 884 are typically made fromdissimilar materials and any such weld or bond may be weaker thandesired. Thus additional mechanical engagement between the two elements,e.g., the knife drive rod 880 and knife body 884, is needed to preventmechanical failure. Tube 881 may be made from any type of metal, e.g.,stainless steel, that will provide a secure weld to knife body 884.

In embodiments, the knife body 884 and the tube 881 are made from thesame material, e.g., stainless steel, to assure a good weld. Theproximal end 882 of the knife body 880 also includes an aperture orkeyway 883 defined therein configured to receive the distal end 889 ofthe knife drive rod 880. More particularly, the distal end 889 of theknife rod 880 is bent at an angle, e.g., 90°, such that during assemblythe distal end 889 may be inserted into aperture 883 to secure the knifedrive rod 880 to the knife body 884. The distal end 889 includes alocking feature 889′ that is enabled once the distal end 889 is insertedinto the aperture 883 during assembly.

The locking feature 889′ may be a twist lock, tab lock, button snap,crimp, rivet or the like that is dimensioned to securely engage thedistal end 889 within aperture 883 upon actuation, e.g., twisting,snapping, crimping, hammering, etc. thereof (FIG. 8C). In addition andduring assembly the tube 881 is seated within slot 887 to capture thetube 881 therein and provide additional mechanical engagement betweenthe knife drive rod 880 and the knife body 884 (See FIG. 8C).

FIGS. 9A and 9B show another embodiment of a knife 985 for engagement toa knife drive rod 980. More particularly, knife 985 includes a knifebody 984 having a distal end 986 and a proximal end 982, the distal end986 including a sharpened edge for cutting tissue and the proximal end982 including a slot 987 defined therein and configured to capture atube 981 crimped, threaded or welded onto a portion of the knife driverod 980. Together the knife 985 and knife drive rod 980 form a knifeassembly 950.

Since the knife drive rod 980 needs to be flexible to accommodatearticulation of the jaw members 110, 120, and the knife body 984 needsto be sufficiently strong to cut through tissue on a repeated basis, theknife drive rod 980 and the knife body 984 are typically made fromdissimilar materials and any such weld or bond may be weaker thandesired. Thus additional mechanical engagement between the two elements,e.g., the knife drive rod 980 and knife body 984, is needed to preventmechanical failure. Tube 981, on the other hand, may be made from anytype of metal, e.g., stainless steel, that will provide a secure weld toknife body 984.

In embodiments, the knife body 984 and the tube 981 are made from thesame material, e.g., stainless steel, to assure a good weld. In additionand during assembly the tube 981 is seated within slot 987 to capturethe tube 981 therein and provide additional mechanical engagementbetween the knife drive rod 980 and the knife body 984 (See FIG. 9C). Asmentioned above, the knife drive rod 980 and the tube 980 are typicallymade from dissimilar metals, e.g., Nitinol and stainless steel,respectively, and, when welded, may produce a weaker weld.

In the particular embodiment of FIGS. 9A and 9B, if the weaker weldbetween the knife drive rod 980 and the tube 981 fails, the strongerbond between the knife body 984 and the tube 981 will remain intactthereby preventing the possibility of the blade 985 coming out of one orboth jaw members, e.g., jaw member 120.

FIG. 10 shows another embodiment of a knife 1085 for engagement to aknife drive rod (not shown). More particularly, knife 1085 includes aknife body 1084 having a distal end 1086 and a proximal end 1082, thedistal end 1086 including a sharpened edge for cutting tissue and theproximal end 1082 configured to mechanically engage a tube 1081 whichmay be crimped, threaded or welded onto the proximal end 1082 along alower edge 1087 of the knife body 1084. Together the knife 1085 andknife drive rod (not shown) form a knife assembly 1050. Tube 1081 may bemade from any type of metal, e.g., stainless steel, that will provide asecure weld to knife body 1084.

In embodiments, the knife body 1084 and the tube 1081 are made from thesame material, e.g., stainless steel, to assure a good weld. The knifedrive rod is secured within the tube 1081 during assembly via crimping,welding or threadable engagement. Engaging the knife drive rod to thetube 1081 which is secured to the lower edge 1087 of the knife body 1084facilitates a more balanced actuation of the knife 1085 duringtranslation since the mechanical engagement of the knife body 1084 andthe tube 1081 is along the centerline (lower edge 1087) of the knife1085.

The present disclosure also describes various methods of engaging aknife drive rod, e.g., knife drive rod 280, 380, 480, 580, 680, 780,880, and 980, to a respective knife, e.g., knife 285, 385, 485, 585,685, 785, 885, 985, 1085. For example, one such method is described withreference to FIGS. 2A and 2B. The method includes: forming a knife 285(e.g., stamping, etching, cutting, pressing, rolling (hot or cold),extruding, etc.) having proximal 282 and distal ends 286, the distal end286 including a sharpened edge; etching (or otherwise forming) anaperture 287 within the proximal end 282 of the knife 285, the aperture287 including a series of fins 283 disposed therein; weaving a distalend of a knife rod 280 through the series of fins 283 in an alternatingmanner; and engaging a cap 281 onto the distal end of the knife driverod 280 to secure the knife drive rod 280 within the aperture 287 of theknife 285. One or more fins 283 may include a recess 283′ formed thereinconfigured to laterally secure the knife drive rod 285 within theaperture 287. The distal end of the drive rod 280 may be weaved throughthe fins 283 and recesses 283′. The aperture 287 may be formed withinknife 285 via etching, cutting, stamping or any other method known inthe art.

FIGS. 3A-3C show another method of engaging a knife drive rod 380 to aknife 385 according the present disclosure. Similar to the embodimentshown in FIGS. 2A and 2B, the method includes: forming a knife 385having proximal 382 and distal ends 386, the distal end 386 including asharpened edge; etching (or otherwise forming) an aperture 387 withinthe proximal end 382 of the knife 385, the aperture 387 including aseries of fins 383 disposed therein; etching or otherwise forming asecond aperture 389 within the proximal end 382 of the knife 385;weaving a distal end of a knife rod 380 through the series of fins 383in an alternating manner; bending a distal end 381 of the knife driverod 380; and engaging the bent distal end 381 into the second aperture389 formed within the proximal end 382 of the knife 385 to secure theknife drive rod 380 within the aperture 387 of the knife 385.

FIGS. 4A and 4B show another method of engaging a knife drive rod 480 toa knife 485 according the present disclosure. Similar to the embodimentsshown above, the method includes: forming a knife 485 having proximal482 and distal ends 486, the distal end 486 including a sharpened edge;etching (or otherwise forming) an aperture 487 within the proximal end482 of the knife 485, the aperture 487 including a pair of opposingcapture tabs 481 a, 481 b disposed therein; engaging (threading,crimping or otherwise capturing) a tube 483 onto a distal end of a knifedrive rod 480; engaging the tube 483 between the two opposing capturetabs 481 a, 481 b to seat the tube 483 within the aperture 487; andsecuring (welding, crimping, or otherwise) the tube 483 to the proximalend 482 of the knife 485 to secure the knife drive rod 480 and tube 483to the knife 485.

FIGS. 5A-5C show another method of engaging a knife drive rod 580 to aknife 585 according the present disclosure. Similar to the embodimentshown above with respect to FIGS. 4A and 4B, the method includes:forming a knife 585 having proximal 582 and distal ends 586, the distalend 586 including a sharpened edge; etching (or otherwise forming) anaperture 587 within the proximal end 582 of the knife 585, the aperture587 including a capture tab 581 disposed therein; engaging (threading,crimping or otherwise capturing) a tube 583 onto a distal end of a knifedrive rod 580; engaging the tube 583 to the capture tab 581 to seat thetube 583 within the aperture 587; and securing (welding, crimping, orotherwise) the tube 583 to the proximal end 582 of the knife 585 tosecure the knife drive rod 580 and tube 583 to the knife 585.

FIGS. 6A-6C show another method of engaging a knife drive rod 680 to aknife 685 according the present disclosure. The method includes: forminga knife 685 having proximal 682 and distal ends 686, the distal end 686including a sharpened edge; etching (or otherwise forming) an aperture687 within the proximal end 682 of the knife 685; engaging (e.g.,welding) a pair of opposing tubes 681 a, 681 b within the aperture 687;feeding the knife drive rod 680 through the pair of tubes 681 a, 681 b;and engaging (e.g., welding or crimping) a second tube 689 to theexposed portion of the knife drive rod 680 between the pair of tubes 681a, 681 b to secure the knife drive rod 680 in place between the tubes681 a, 681 b. Knife drive rod 680 and the second tube 689 may be madefrom the same material to provide a strong weld. The knife drive rod 680may also be threaded through the pair of tubes 681 a, 681 b to enhancethe mechanical connection. The tubes 681 a, 681 b may be made from thesame material as the knife 685 to enhance the weld and provideadditional strength, stiffness, and/or durability.

FIGS. 7A-7C show another method of engaging a knife drive rod 780 to aknife 785 according the present disclosure. Similar to the embodimentsshown above with respect to FIGS. 4A and 4B and FIGS. 3A-3C, the methodincludes: forming a knife 785 having proximal 782 and distal ends 786,the distal end 786 including a sharpened edge; etching (or otherwiseforming) an aperture 787 within the proximal end 782 of the knife 785;etching or otherwise forming a second aperture 789 within the proximalend 782 of the knife 785; engaging (threading, crimping or otherwisecapturing) a tube 781 onto a distal end 783 of a knife drive rod 780;bending the distal end 783 of the knife drive rod 780; seating the tube781 within the aperture 787; and engaging the bent distal end 783 intothe second aperture 789 formed within the proximal end 782 of the knife785 to secure the tube 781 within the aperture 787 of the knife 785 andsecure the bent distal end 783 to the proximal end 782 of the knife 785.

FIGS. 8A-8C show another method of engaging a knife drive rod 880 to aknife 885 according the present disclosure. Similar to the embodimentsshown above with respect to FIGS. 7A-7C, the method includes: forming aknife 885 having proximal 882 and distal ends 886, the distal end 886including a sharpened edge; etching (or otherwise forming) an aperture887 within the proximal end 882 of the knife 885; etching or otherwiseforming a slot 883 within the proximal end 882 of the knife 885;engaging (threading, crimping or otherwise capturing) a tube 881 onto adistal end 889 of a knife drive rod 880; bending the distal end 889 ofthe knife drive rod 880; seating the tube 881 within the aperture 887;engaging the bent distal end 889 into the slot 883 formed within theproximal end 882 of the knife 885; actuating a locking feature 889′(e.g., twist lock, tab lock, button snap, crimp, rivet or the like) toengage and secure (via twisting, snapping, crimping, hammering, etc.)the distal end 889 within the slot 883 and secure the tube 881 withinthe aperture 887 of the knife 885.

FIGS. 9A-9C show another method of engaging a knife drive rod 980 to aknife 985 according the present disclosure. Similar to many of theabove-described embodiments shown above with respect to the variousfigures, the method includes: forming a knife 985 having proximal 982and distal ends 986, the distal end 986 including a sharpened edge;etching (or otherwise forming) an aperture 987 within the proximal end982 of the knife 985; engaging (threading, crimping or otherwisecapturing) a tube 981 onto a distal end of a knife drive rod 980;seating the tube 981 within the aperture 987; and securing the tube 981within the aperture 987 via welding, crimping, etc. As mentioned above,the knife body 984 and the tube 981 are made from the same material,e.g., stainless steel, to assure a good weld.

In addition and during assembly the tube 981 is seated within slot 987to capture the tube 981 therein and provide additional mechanicalengagement between the knife drive rod 980 and the knife body 984 (SeeFIG. 9C). As mentioned above, the knife drive rod 980 and the tube 980are typically made from dissimilar metals, e.g., Nitinol and stainlesssteel, respectively, and, when welded, may produce a weaker weld. If theweaker weld between the knife drive rod 980 and the tube 981 fails, thestronger bond between the knife body 984 and the tube 981 will remainintact thereby preventing the possibility of the blade 985 coming out ofone or both jaw members, e.g., jaw member 120.

FIG. 10 shows another method of engaging a knife drive rod 1080 to aknife 1085 according the present disclosure. The method includes forminga knife 1085 having proximal 1082 and distal ends 1086, the distal end1086 including a sharpened edge; engaging (e.g., welding or othermechanical attachment) a tube 1081 to a lower edge 1087 of the knife1085; and engaging (threading, crimping or otherwise capturing) a distalend of a knife drive rod (not shown) within the tube 1081. Tube 1081 maybe made from any type of metal, e.g., stainless steel, that will providea secure weld to knife body 1084 (which is also made from a similarmaterial, e.g., stainless steel) to assure a good weld.

Engaging the knife drive rod to the tube 1081 (which is secured to thelower edge 1087 of the knife body 1084) facilitates a more balancedactuation of the knife 1085 during translation since the mechanicalengagement of the knife body 1084 and the tube 1081 is along thecenterline (lower edge 1087) of the knife 1085.

The various embodiments disclosed herein may also be configured to workwith robotic surgical systems and what is commonly referred to as“Telesurgery.” Such systems employ various robotic elements to assistthe clinician and allow remote operation (or partial remote operation)of surgical instrumentation. Various robotic arms, gears, cams, pulleys,electric and mechanical motors, etc. may be employed for this purposeand may be designed with a robotic surgical system to assist theclinician during the course of an operation or treatment. Such roboticsystems may include remotely steerable systems, automatically flexiblesurgical systems, remotely flexible surgical systems, remotelyarticulating surgical systems, wireless surgical systems, modular orselectively configurable remotely operated surgical systems, etc.

The robotic surgical systems may be employed with one or more consolesthat are next to the operating theater or located in a remote location.In this instance, one team of clinicians may prep the patient forsurgery and configure the robotic surgical system with one or more ofthe instruments disclosed herein while another clinician (or group ofclinicians) remotely controls the instruments via the robotic surgicalsystem. As can be appreciated, a highly skilled clinician may performmultiple operations in multiple locations without leaving his/her remoteconsole which can be both economically advantageous and a benefit to thepatient or a series of patients.

For a detailed description of exemplary medical work stations and/orcomponents thereof, reference may be made to U.S. Patent ApplicationPublication No. 2012/0116416, and PCT Application Publication No.WO2016/025132, the entire contents of each of which are incorporated byreference herein.

Persons skilled in the art will understand that the structures andmethods specifically described herein and shown in the accompanyingfigures are non-limiting exemplary embodiments, and that thedescription, disclosure, and figures should be construed merely asexemplary of particular embodiments. It is to be understood, therefore,that the present disclosure is not limited to the precise embodimentsdescribed, and that various other changes and modifications may beeffected by one skilled in the art without departing from the scope orspirit of the disclosure. Additionally, the elements and features shownor described in connection with certain embodiments may be combined withthe elements and features of certain other embodiments without departingfrom the scope of the present disclosure, and that such modificationsand variations are also included within the scope of the presentdisclosure. Accordingly, the subject matter of the present disclosure isnot limited by what has been particularly shown and described.

While several embodiments of the disclosure have been shown in thedrawings, it is not intended that the disclosure be limited thereto, asit is intended that the disclosure be as broad in scope as the art willallow and that the specification be read likewise. Therefore, the abovedescription should not be construed as limiting, but merely asexemplifications of particular embodiments. Those skilled in the artwill envision other modifications within the scope and spirit of theclaims appended hereto. For example, the knife body and tube do notnecessarily have to be made from the exact same materials. Similarmaterials, or any two materials that can be welded together to allow fora durable weld joint could be used.

What is claimed is:
 1. A knife assembly for use with a surgicalinstrument, comprising: a knife including proximal and distal ends, theproximal end including an aperture defined therein including a series ofspaced apart fins extending thereacross; a knife drive rod configured tooperably engage the fins to secure the knife drive rod to the knife; anda retention mechanism operably disposed at a distal end of the knifedrive rod configured to secure the knife drive rod in engagement betweenthe fins.